Fatigue resistant blade outer air seal

ABSTRACT

A blade outer air seal segment including a radially outward surface, a radially inward surface oriented away from the radially outward surface, and a cooling channel located between the radially outward surface and the radially inward surface. The blade outer air seal segment also including a stress-relief boss extending into the cooling channel and an inlet orifice fluidly coupled to the cooling channel through the stress-relief boss. The blade outer air seal segment further including a stress-relief recess. The stress-relief boss being located within the stress relief recess.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.16/434,630 filed on Jun. 7, 2019, the entire contents of which areincorporated herein by reference thereto.

BACKGROUND

The subject matter disclosed herein generally relates to gas turbineengines and, more particularly, to a blade outer air seal (BOAS) havingfatigue resistant cooling inlets and methods of forming the same.

A gas turbine engine generally includes a fan section, a compressorsection, a combustor section, and a turbine section. The fan sectiondrives air along a bypass flow path and a core flow path. In general,during operation, air is pressurized in the compressor section and thenmixed with fuel and ignited in the combustor section to generatecombustion gases. The combustion gases flow through the turbine section,which extracts energy from the combustion gases to power the compressorsection and generate thrust.

The blade assemblies of the turbine section generally include a BOAS toreduce flow leakage over the blade tips. The BOAS is subjected toextremely hot combustion gases. To cool the BOAS, cooling air from asecondary air flow system may be provided to internal cooling channelsformed within the body of the BOAS. The cooling air may enter theinternal cooling channels through inlet holes formed through the BOAS.The inlet holes tend to experience increased fatigue due to the tensilestresses resulting from the temperature difference between the flow-pathside of the BOAS and the cooled side of the BOAS (i.e., the sideproximate the combustion gases and the side proximate the cooling flow).

SUMMARY

According to an embodiment, a blade outer air seal segment is provided.The blade outer air seal segment including a radially outward surface, aradially inward surface oriented away from the radially outward surface,and a cooling channel located between the radially outward surface andthe radially inward surface. The blade outer air seal segment alsoincluding a stress-relief boss extending into the cooling channel and aninlet orifice fluidly coupled to the cooling channel through thestress-relief boss. The blade outer air seal segment further including astress-relief recess. The stress-relief boss being located within thestress relief recess.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the cooling channel isdefined, at least partially, by a radially outward channel surface and aradially inward channel surface. The stress-relief boss extends awayfrom the radially outward channel surface to a surface of thestress-relief boss.

In addition to one or more of the features described above, or as analternative, further embodiments may include a raised portion of theradially outward surface. The radially outward channel surface islocated radially outward of the radially inward channel surface. Theinlet orifice extends from the raised portion of the radially outwardsurface to the surface of the stress-relief boss.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the surface of thestress-relief boss is about parallel to at least one of the radiallyinward channel surface and the radially outward channel surface.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the stress-relief bossextends to a surface of the stress-relief boss. A radial height of thecooling channel between the radially outward channel surface and theradially inward channel surface is greater than a radial height of thecooling channel between the surface of the stress-relief boss and theradially inward channel surface.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the stress-relief bossis concentric to the inlet orifice.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the stress-relief bossis concentric to the stress-relief recess.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the cooling channel isdefined, at least partially, by a radially outward channel surface and aradially inward channel surface. The stress-relief recess extends intothe radially outward channel surface to a base of the stress-reliefrecess.

In addition to one or more of the features described above, or as analternative, further embodiments may include that a radial height of thecooling channel between the radially outward channel surface and theradially inward channel surface is less than a radial height of thecooling channel between the base of the stress-relief recess and theradially inward channel surface.

According to another embodiment, a turbine section of a gas turbineengine is provided. The turbine section including: a blade configured torotate about an axis and a blade outer air seal segment radially outwardof the blade. The blade outer air seal segment including a radiallyoutward surface, a radially inward surface oriented away from theradially outward surface, and a cooling channel located between theradially outward surface and the radially inward surface. The bladeouter air seal segment also including a stress-relief boss extendinginto the cooling channel and an inlet orifice fluidly coupled to thecooling channel through the stress-relief boss. The blade outer air sealsegment further including a stress-relief recess. The stress-relief bossbeing located within the stress relief recess.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the cooling channel isdefined, at least partially, by a radially outward channel surface and aradially inward channel surface; and wherein the stress-relief bossextends away from the radially outward channel surface to a surface ofthe stress-relief boss.

In addition to one or more of the features described above, or as analternative, further embodiments may include a raised portion of theradially outward surface. The radially outward channel surface islocated radially outward of the radially inward channel surface. Theinlet orifice extends from the raised portion of the radially outwardsurface to the surface of the stress-relief boss.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the surface of thestress-relief boss is about parallel to at least one of the radiallyinward channel surface and the radially outward channel surface.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the stress-relief bossextends to a surface of the stress-relief boss. A radial height of thecooling channel between the radially outward channel surface and theradially inward channel surface is greater than a radial height of thecooling channel between the surface of the stress-relief boss and theradially inward channel surface.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the stress-relief bossis concentric to the inlet orifice.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the stress-relief bossis concentric to the stress-relief recess.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the cooling channel isdefined, at least partially, by a radially outward channel surface and aradially inward channel surface. The stress-relief recess extends intothe radially outward channel surface to a base of the stress-reliefrecess.

In addition to one or more of the features described above, or as analternative, further embodiments may include that a radial height of thecooling channel between the radially outward channel surface and theradially inward channel surface is less than a radial height of thecooling channel between the base of the stress-relief recess and theradially inward channel surface.

According to another embodiment, a method of forming a blade outer airseal segment is provided. The method including that a blade outer airseal material is deposited around a core. The core being configured toform a cooling channel in the blade outer air seal segment. The coreincludes a raised section and a recess within the raised section. Athickness of the core at the recess is less than a thickness of achannel portion of the core and a thickness of the core at the raisedsection is greater than the thickness of the channel portion of thecore. The method also including that an inlet orifice is formed throughthe blade outer air seal material in a location of the recess.

In addition to one or more of the features described above, or as analternative, further embodiments may include that forming the inletorifice includes using electrical discharge machining to form the inletorifice.

The foregoing features and elements may be combined in variouscombinations without exclusivity, unless expressly indicated otherwise.These features and elements as well as the operation thereof will becomemore apparent in light of the following description and the accompanyingdrawings. It should be understood, however, that the followingdescription and drawings are intended to be illustrative and explanatoryin nature and non-limiting.

BRIEF DESCRIPTION

The following descriptions should not be considered limiting in any way.With reference to the accompanying drawings, like elements are numberedalike:

FIG. 1 is a partial cross-sectional illustration of a gas turbineengine;

FIG. 2 illustrates a schematic cross-section of a portion of a highpressure turbine section of the gas turbine engine of FIG. 1 , inaccordance with an embodiment of the present disclosure;

FIG. 3 illustrates a perspective view of a BOAS segment, in accordancewith an embodiment of the present disclosure;

FIG. 4A illustrates a perspective view of an inlet orifice of the BOASsegment of FIG. 3 , in accordance with an embodiment of the presentdisclosure;

FIG. 4B illustrates a cross-section view of the inlet orifice of FIG. 4Ataken along the line 4B-4B in FIG. 4A, in accordance with an embodimentof the present disclosure;

FIG. 5 illustrates a perspective view of core configured to form a BOAScooling channels and having a stress-relief boss corresponding to aninlet orifice location and a stress-relief recess encircling thestress-relief boss, in accordance with an embodiment of the presentdisclosure; and

FIG. 6 illustrates a method of making a BOAS segment having a fatigueresistant inlet orifice, in accordance with an embodiment of the presentdisclosure.

The detailed description explains embodiments of the present disclosure,together with advantages and features, by way of example with referenceto the drawings.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosedapparatus and method are presented herein by way of exemplification andnot limitation with reference to the Figures.

FIG. 1 schematically illustrates a gas turbine engine 20. The gasturbine engine 20 is disclosed herein as a two-spool turbofan thatgenerally incorporates a fan section 22, a compressor section 24, acombustor section 26 and a turbine section 28. The fan section 22 drivesair along a bypass flow path B in a bypass duct, while the compressorsection 24 drives air along a core flow path C for compression andcommunication into the combustor section 26 then expansion through theturbine section 28. Although depicted as a two-spool turbofan gasturbine engine in the disclosed non-limiting embodiment, it should beunderstood that the concepts described herein are not limited to usewith two-spool turbofans as the teachings may be applied to other typesof turbine engines including three-spool architectures.

The exemplary engine 20 generally includes a low speed spool 30 and ahigh speed spool 32 mounted for rotation about an engine centrallongitudinal axis A relative to an engine static structure 36 viaseveral bearing systems 38. It should be understood that various bearingsystems 38 at various locations may alternatively or additionally beprovided, and the location of bearing systems 38 may be varied asappropriate to the application.

The low speed spool 30 generally includes an inner shaft 40 thatinterconnects a fan 42, a low pressure compressor 44 and a low pressureturbine 46. The inner shaft 40 is connected to the fan 42 through aspeed change mechanism, which in exemplary gas turbine engine 20 isillustrated as a geared architecture 48 to drive the fan 42 at a lowerspeed than the low speed spool 30. The high speed spool 32 includes anouter shaft 50 that interconnects a high pressure compressor 52 and highpressure turbine 54. A combustor 56 is arranged in exemplary gas turbine20 between the high pressure compressor 52 and the high pressure turbine54. An engine static structure 36 is arranged generally between the highpressure turbine 54 and the low pressure turbine 46. The engine staticstructure 36 further supports bearing systems 38 in the turbine section28. The inner shaft 40 and the outer shaft 50 are concentric and rotatevia bearing systems 38 about the engine central longitudinal axis Awhich is collinear with their longitudinal axes.

The core airflow is compressed by the low pressure compressor 44 thenthe high pressure compressor 52, mixed and burned with fuel in thecombustor 56, then expanded over the high pressure turbine 54 and lowpressure turbine 46. The turbines 46, 54 rotationally drive therespective low speed spool 30 and high speed spool 32 in response to theexpansion. It will be appreciated that each of the positions of the fansection 22, compressor section 24, combustor section 26, turbine section28, and fan drive gear system 48 may be varied. For example, gear system48 may be located aft of combustor section 26 or even aft of turbinesection 28, and fan section 22 may be positioned forward or aft of thelocation of gear system 48.

The engine 20 in one example is a high-bypass geared aircraft engine. Ina further example, the engine 20 bypass ratio is greater than about six(6), with an example embodiment being greater than about ten (10), thegeared architecture 48 is an epicyclic gear train, such as a planetarygear system or other gear system, with a gear reduction ratio of greaterthan about 2.3 and the low pressure turbine 46 has a pressure ratio thatis greater than about five. In one disclosed embodiment, the engine 20bypass ratio is greater than about ten (10:1), the fan diameter issignificantly larger than that of the low pressure compressor 44, andthe low pressure turbine 46 has a pressure ratio that is greater thanabout five 5:1. Low pressure turbine 46 pressure ratio is pressuremeasured prior to inlet of low pressure turbine 46 as related to thepressure at the outlet of the low pressure turbine 46 prior to anexhaust nozzle. The geared architecture 48 may be an epicycle geartrain, such as a planetary gear system or other gear system, with a gearreduction ratio of greater than about 2.3:1. It should be understood,however, that the above parameters are only exemplary of one embodimentof a geared architecture engine and that the present disclosure isapplicable to other gas turbine engines including direct driveturbofans.

A significant amount of thrust is provided by the bypass flow B due tothe high bypass ratio. The fan section 22 of the engine 20 is designedfor a particular flight condition—typically cruise at about 0.8 M achand about 35,000 feet (10,688 meters). The flight condition of 0.8 Machand 35,000 ft (10,688 meters), with the engine at its best fuelconsumption—also known as “bucket cruise Thrust Specific FuelConsumption (‘TSFC’)”—is the industry standard parameter of lbm of fuelbeing burned divided by lbf of thrust the engine produces at thatminimum point. “Low fan pressure ratio” is the pressure ratio across thefan blade alone, without a Fan Exit Guide Vane (“FEGV”) system. The lowfan pressure ratio as disclosed herein according to one non-limitingembodiment is less than about 1.45. “Low corrected fan tip speed” is theactual fan tip speed in ft/sec divided by an industry standardtemperature correction of [(Tram ° R)/(518.7 ° R)]^(0.5). The “Lowcorrected fan tip speed” as disclosed herein according to onenon-limiting embodiment is less than about 1150 ft/second (350.5 m/sec).

Referring now to FIG. 2 , with continued reference to FIG. 1 , a portionof the high pressure turbine 54 is illustrated, in accordance with anembodiment of the present disclosure. The high pressure turbine 54 mayinclude vane assemblies 100 and blade assemblies 102 (one shown) axiallyinterspersed with the vane assemblies 100. The vane assemblies 100 donot rotate and the blade assemblies 102 rotate. The vane assemblies 100each include a plurality of vanes 106 positioned about the enginecentral longitudinal axis A. Each of the vanes 106 may extend between aninner vane platform 112 and an outer vane platform 114. The outer vaneplatform 114 may be configured to couple, or otherwise supportattachment of, the vane assemblies 100 to a turbine case structure 116.The turbine case structure 116 may form a portion of the engine staticstructure 36 illustrated in FIG. 1 . The vane assemblies 100 comprisestatic structures that do not rotate relative to the engine centrallongitudinal axis A. The vane assemblies 100 may help direct the flow offluid (i.e., airflow along core flow path C) received by and output fromthe blade assemblies 102.

The blade assemblies 102 each include a plurality of blades 110configured for rotation about the engine central longitudinal axis A.For example, the blades 110 may rotate in response to receiving a flowof fluid (e.g., combustion gases) from the combustor 56 of FIG. 1 .Power from the flow may be converted to mechanical power, or torque, bythe blades 110. The blade assemblies 102 may also include a blade outerair seal 120 (BOAS 120). A blade outer air seal support 122 (BOASsupport 122) may couple, or otherwise secure, the BOAS 120 to theturbine case structure 116.

The BOAS 120 is disposed radially outward of the blades 110. The BOAS120 is configured to provide a seal to reduce or prevent hot gases fromleaking over the tips of the blades 110. In various embodiments, theBOAS 120 may be segmented. For example, the BOAS 120 may comprise aplurality of arcuate BOAS segments arranged in circumferential seriesaround the engine central longitudinal axis A.

Referring now to FIG. 3 , with continued reference to FIGS. 1-2 , a BOASsegment 130 of the BOAS 120 is illustrated, in accordance with anembodiment of the present disclosure. The BOAS segment 130 includes aradially inward (or first) surface 134 and a radially outward (orsecond) surface 136. The radially inward surface 134 is oriented awayfrom the radially outward surface 136. When installed in the bladeassemblies 102 of FIG. 2 , the radially inward surface 134 of the BOASsegments 130 is oriented toward blades 110.

The BOAS segment 130 includes a forward wall 140 and an aft wall 142opposite the forward wall 140. The forward wall 140 extends in aradially outward direction and may define a forward edge 144 of BOASsegment 130. The aft wall 142 extends in a radially outward directionand may define an aft edge 146 of the BOAS segment 130. In variousembodiments, the aft wall 142 may include one or more aftward extendingflange(s) 154 and one or more forward extending flange(s) 156. Theforward wall 140 may include one or more aftward extending flange(s)158. The aftward extending flanges 158 may extend aftward from anaftward oriented surface 148 of the forward wall 140. In variousembodiments, the forward wall 140 may also or alternatively include oneor more forward extending flange(s) 147. The forward extending flange(s)147 of the forward wall 140 may extend forward from a forward orientedsurface 145 of the forward wall 140.

The BOAS segment 130 includes a first circumferential wall 150 and asecond circumferential wall 152 opposite the first circumferential wall150. The first circumferential wall 150 extending from the forward wall140 to the aft wall 142. The second circumferential wall 152 extendingfrom the forward wall 140 to the aft wall 142. The BOAS segment 130 maybe arranged in circumferential series with a plurality of BOAS segments130 such that the first circumferential wall 150 of a first BOAS segment130 is circumferentially adjacent to the second circumferential wall 152of a second BOAS segment 130.

In an embodiment, the BOAS segment 130 includes one or more inletorifice(s) 170. Stated differently, BOAS segment 130 defines the inletorifices 170. In various embodiments, inlet orifices 170 are formed inthe radially outward portion 136 of the BOAS segment 130. In thisregard, the inlet orifices 170 may be formed through radially outwardportion 136 of the BOAS segment 130. The inlet orifices 170 may beformed through raised portions 172 of the BOAS segment 130.

Referring now to FIGS. 4A and 4B, with continued reference to FIGS. 1-3, additional details of the inlet orifice 170 formed through theradially outward portion 136 of the BOAS segment 130 are illustrated, inaccordance with an embodiment of the present disclosure.

The inlet orifices 170 formed through the raised portion 172 of the BOASsegment 130 are illustrated, in accordance with various embodiments. Aradial height, or thickness, H7 of the BOAS segment 130 at the raisedportion 172 is greater than the radial height H2 of the BOAS segment 130at the radially outward surface 136. The radial height H7 is measuredbetween the radially inward surface 134 of the BOAS segment 130 and thesurface 174 of the raised portion 172. The surface 174 of the raisedportion 172 is oriented opposite, or generally away from, radially theinward surface 134. In various embodiments, the radial height H7 of theBOAS segment 130 at the raised portion 172 is less than the radialheight H1 of BOAS segment 130 at the first circumferential wall 150.

A radial height, or thickness, H1 of the BOAS segment 130 at the firstcircumferential wall 150 is equal to or greater than a radial height, orthickness, H2 of the BOAS segment 130 at the radially outward surface136. The radial height H1 is measured between the radially inwardsurface 134 of the BOAS segment 130 and the surface 160 of the firstcircumferential wall 150. The surface 160 of the first circumferentialwall 150 is oriented opposite, or generally away from, the radiallyinward surface 134. The radial height H2 is measured between theradially inward surface 134 and the radially outward surface 136 of theBOAS segment 130. In an embodiment, the second circumferential wall 152includes a radial height equal to the radial height H1 of firstcircumferential wall 150.

The BOAS segment 130 defines one or more internal cooling channel(s)180. The cooling channels 180 may form a cooling circuit through theBOAS segment 130. Cooling airflow in the space over (i.e., radiallyoutward from) radially outward surface 136 may be provided to thecooling channels 180 through the inlet orifices 170. Stated differently,cooling airflow may flow through the inlet orifice 170 and into thecooling channel 180.

The cooling channel 180 is enclosed within the BOAS segment 130 betweenthe radially outward surface 136 and the radially inward surface 134.The cooling channel 180 may be defined, at least partially, by aradially outward channel surface 182 and a radially inward channelsurface 184 opposite the radially outward channel surface 182. Theradially outward channel surface 182 is located radially outward of theradially inward channel surface 184. The radially outward channelsurface 182 may be located at a radial height H3 away from the radiallyinward channel surface 184. Stated differently, the radial height H3 isa height or thickness of the cooling channel 180.

A stress-relief boss 162 extends into the cooling channel 180. Thestress-relief boss 162 extends to a surface 164, as shown in FIG. 4B.The inlet orifice 170 extends from the surface 174 of the raised portion172 to the surface 164 of the stress-relief boss 162. In an embodiment,the surface 164 of the stress-relief boss 162 may be about parallel withat least one of the radially inward channel surface 184 and the radiallyoutward channel surface 182. The stress-relief boss 162 may be formed onthe radially outward channel surface 182. The stress-relief boss 162extends away from the radially outward channel surface 182 into thecooling channel 180 and towards the radially inward channel surface 184.The stress-relief boss 162 is located proximate the inlet orifice 170.In an embodiment, the inlet orifice 170 may be formed through thestress-relief boss 162 of BOAS segment 130. The inlet orifices 170 arefluidly coupled to cooling channels 180. In an embodiment, the inletorifice 170 is fluidly coupled to the cooling channel 180 through thestress-relief boss 162.

The radial height H3, H4, H8 of the cooling channel 180 decreasesproximate the stress-relief boss 162. Stated differently, the radialheight H3 of the cooling channel between the radially outward channelsurface 182 and the radially inward channel surface 184 is greater thanthe radial height H4 of the cooling channel between a surface 164 of thestress-relief boss 162 and the radially inward channel surface 184.

The BOAS segment 130 includes a radially outward wall 163 interposedbetween the radially outward surface 136 and radially outward channelsurface 182. The radially outward wall 163 also extends between theradially outward surface 136 and a surface 164 of the stress-relief boss162. A thickness H6 of the radially outward wall 163 between theradially outward surface 136 and a surface 164 of the stress-relief boss162 is greater than a thickness H5 of the radially outward wall 163between the radially outward surface 136 and radially outward channelsurface 182. In other words a thickness of the radially outward wall 163increases proximate the stress-relief boss 162.

In an embodiment, the BOAS segments 130 includes a stress-relief recess190. The stress-relief is formed in the radially outward channel surface184. The stress-relief boss 162 is located within the stress reliefrecess 190. The stress-relief recess 190 may encircle the stress-reliefboss 162, as illustrated in FIG. 4B. The stress-relief recess 190extends into the radially outward channel surface 182 to a base 192 ofthe stress-relief recess 190. Stated differently, the stress-reliefrecess 190 bottoms out at the base 192. The stress-relief recess 190 mayextending into the radially outward channel surface 182 a radial heightH9, as illustrated in FIG. 4B. The radial height H3, H4, H8 of thecooling channel 180 increases at the stress-relief recess 190. Stateddifferently, the radial height H3 of the cooling channel between theradially outward channel surface 182 and the radially inward channelsurface 184 is less than the radial height H8 of the cooling channelbetween the base 192 of the stress-relief recess 190 and the radiallyinward channel surface 184.

In an embodiment, the stress-relief boss 162 may be cylindricallyshaped. In this regard, a cross-section of the stress-relief boss 162taken along a plane generally parallel to the surface 164 may becircular. The inlet orifice 170 may be cylindrically shaped. In thisregard, a cross-section of the inlet orifice 170 taken along a planegenerally parallel to the surface 164 may be circular. In an embodiment,the stress-relief recess 190 may be cylindrically shaped. In thisregard, a cross-section of the stress-relief recess 190 taken along aplane generally parallel to the base 192 may be circular. In variousembodiments, a cross-section of the stress-relief boss 162 across-section the inlet orifice 170, and/or the stress-relief recess 190taken along a plane generally parallel to the base 192 may comprise anelliptical, an oval, a rectangular, a polygonal, or any other desiredshape.

The stress-relief boss 162 may be concentric to the inlet orifice 170such that a radius R1 of the inlet office 170 and a radius R2 of thestress-relief boss 162 are measured from the same axis B. A diameter D1of inlet orifice 170 is less than a diameter D2 of stress-relief boss162.

The stress-relief recess 190 may be concentric to the inlet orifice 170and the stress-relief boss 162 such that the radius R1 of the inletoffice 170, the radius R2 of the stress-relief boss 162, and a radius R3of the stress-relief boss 162 are measured from the same axis B. Thediameter D1 of the inlet orifice 170 is less than a diameter D2 of thestress-relief boss 162 and the diameter D2 of stress-relief boss 162 isless than a diameter D3 of stress-relief recess 162.

Advantageously, the stress-relief boss 162 and the stress-relief recess190 tends to shield the inlet orifice 170 from the tensile stress fieldcreated by the thermal gradient between the radially inward surface 134and the radially outward surface 136. The stress-relief boss 162 may besubjected to the tensile stress field, but experiences a lower stressthan the inlet orifice 170 alone extending to the radially outwardchannel surface 182 (i.e., cooling circuits which do not includestress-relief bosses 162 or the stress-relief recess 190). The BOASsegment 130 tends to exhibit improved fatigue capability, which mayallow the BOAS 120 to be employed in greater temperatures and/or exposedto increased temperatures for a longer durations of time. Alsoadvantageously, decreasing the radial height (i.e., from H3 to H4) ofthe cooling channel 180 proximate the inlet orifice 170 improves theimpingement coefficient of cooling air flow through the inlet orifice170 towards the radially inward channel surface 184. Alsoadvantageously, by adding the stress-relief recess 190 the radial heightH6 of the stress-relief boss 162 may be reduced, which reduces theimpedance of the stress-relief boss 162 on lateral airflow within thecooling channel 180.

Referring now to FIG. 5 , with continued reference to FIGS. 1-4A, and4B, a core 200 configured to form the cooling channels 180 and thestress-relief boss 162 is illustrated, in accordance with an embodimentof the present disclosure. The core 200 may comprise metal, composite,or any other suitable material. In various embodiments, the core 200 maybe a ceramic core. The core 200 includes one or more recesses 202. Thelocation of the recess 202 corresponds to the location of the inletorifice 170 of FIGS. 3, 4A, and 4B. In various embodiments, the locationof recesses 202 corresponds to the stress-relief bosses 162 of BOASsegment 130, of FIG. 4 . The recesses 202 are formed on the channelportions 204 of the core 200. A thickness of core 200 at recess 202 isless than a thickness of core 200 at channel portion 204. The thicknessof core 200 at recess 202 is equal to the radial height H4 in FIG. 4B.The thickness of core 200 at the channel portion 204 is equal to theradial height H6.

In an embodiment, the location of the raised section 206 corresponds tothe stress-relief recess 190 of BOAS segment 130, of FIG. 4 . The raisedsection is formed on the channel portions 204 of the core 200. Athickness of core 200 at the raised section is greater than a thicknessof core 200 at channel portion 204. The thickness of core 200 at raisedsection 206 is equal to the radial height H9 in FIG. 4B. The thicknessof core 200 at the channel portion 204 is equal to the radial height H6.

Referring now to FIG. 6 , with continued reference to FIGS. 1-4A, 4B,and 5, a method 250 of forming a BOAS segment 130 having inlet orifices170 that are fatigue resistant is illustrated, in accordance with anembodiment of the present disclosure. The method 250 may include thesteps of depositing a BOAS material around a core 200 (step 252). Thecore 200 being configured to form a cooling channel 180 in the BOASsegment 130 and including a raised section 206 and a recess 202 withinthe raised section 206. The raised section 206 may encircle the recess206, as illustrated in FIG. 5 . A thickness of the core 200 is reducedat the recess 202. A thickness of the core 200 is increased at theraised section 206. The method 250 may further comprise removing thecore 200 (step 254). For example, the core 200 may be leached out of theBOAS material forming the BOAS segment 130. The method 250 furthercomprises forming an inlet orifice 170 through the BOAS segment 130(step 256). In an embodiment, the inlet orifice 170 is formed within therecess 202.

In various embodiments, step 256 may include forming the inlet orificeusing electrical discharge machining (EDM). Using EDM to form the inletorifices 170 tends to be associated with greater reductions in fatiguecapability, as compared to milling or drilling the inlet orifices 170.In various embodiments, step 256 may include forming the inlet orifice170 using milling, drilling, or any other suitable technique.

While the inlet orifices 170 and method 250 are described in relation toa BOAS segment 130, it is further contemplated and understood that thefeatures and techniques described herein may be applied to other partshaving cooling circuits. For example, the cooling channels 180, and theinlet orifices 170 may be formed in the inner vane platform 112 and/orthe outer vane platform 114 in FIG. 2 .

The term “about” is intended to include the degree of error associatedwith measurement of the particular quantity based upon the equipmentavailable at the time of filing the application.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the presentdisclosure. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,element components, and/or groups thereof

While the present disclosure has been described with reference to anexemplary embodiment or embodiments, it will be understood by thoseskilled in the art that various changes may be made and equivalents maybe substituted for elements thereof without departing from the scope ofthe present disclosure. In addition, many modifications may be made toadapt a particular situation or material to the teachings of the presentdisclosure without departing from the essential scope thereof.Therefore, it is intended that the present disclosure not be limited tothe particular embodiment disclosed as the best mode contemplated forcarrying out this present disclosure, but that the present disclosurewill include all embodiments falling within the scope of the claims.

What is claimed is:
 1. A method of forming a blade outer air sealsegment, comprising: depositing a blade outer air seal material around acore, the core being configured to form a cooling channel in the bladeouter air seal segment, wherein the core comprises a raised section anda recess within the raised section, wherein a thickness of the core atthe recess is less than a thickness of a channel portion of the core,and wherein a thickness of the core at the raised section is greaterthan the thickness of the channel portion of the core; and forming aninlet orifice through the blade outer air seal material in a location ofthe recess.
 2. The method of claim 1, wherein forming the inlet orificecomprises using electrical discharge machining to form the inletorifice.